Claims
- 1. A fuel injector for use with an internal combustion engine, the fuel injector comprising:a valve group subassembly including: a valve body extending along a longitudinal axis, the valve body being connected to a non-magnetic sleeve; a valve seat secured to the valve body, the valve seat defining an outlet opening through which fuel flows; an armature movable along the longitudinal axis with respect to the valve body; and a valve ball coupled to the armature, the valve ball being moved between an open position wherein the valve ball is spaced from the valve seat such that fuel flow through the outlet opening is permitted and a closed position wherein the valve ball contiguously engages the valve seat such that fuel flow is prevented; a first fastening surface; and a coil group subassembly including: a solenoid coil operable to displace the armature with respect to the valve; and a housing generally surrounding the solenoid coil and matingly engaging the valve body of the valve group subassembly; and a second fastening surface fixed in contiguous engagement with the first fastening surface so that the valve group subassembly is secured to the coil group subassembly.
- 2. The fuel injector according to claim 1 wherein the valve group subassembly further includes:a fuel tube extending along the longitudinal axis from an upstream end to a downstream end proximate to the valve body; an adjusting tube disposed within the fuel tube; and a spring applying a biasing force urging the valve ball toward the closed position, the spring extending between the adjusting tube and the armature.
- 3. The fuel injector according to claim 2, wherein the valve group subassembly includes the fuel tube connecting to the non-magnetic sleeve.
- 4. The fuel injector according to claim 1, wherein the coil group subassembly further includes:a bobbin defining a winding form for the solenoid coil; and an overmold generally encasing the housing.
- 5. The fuel injector according to claim 4, wherein a portion of the housing projecting beyond the over-mold and connecting to a shoulder on the valve body, and the housing portion is welded to the valve body shoulder.
- 6. The fuel injector according to claim 1, wherein the armature includes an upstream portion receiving fuel, a downstream portion including a fixture securing the valve ball, and an intermediate portion between the upstream and downstream portions.
- 7. The fuel injector according to claim 6, wherein the intermediate portion includes a bore extending along the longitudinal axis and a passage extending from the bore to an exterior surface of the armature.
- 8. The fuel injector according to claim 6, wherein the intermediate portion includes a tubular cylinder and the downstream portion includes an open end of the tubular cylinder.
- 9. The fuel injector according to claim 6, wherein the downstream portion includes a conical depression.
- 10. The fuel injector according to claim 6, wherein the valve ball is a sphere selected from a group consisting of a ball bearing and a gage ball.
- 11. The fuel injector according to claim 5, wherein the over-mold includes a first connector housing partially surrounding at least one electrical connector.
- 12. A method of assembling a fuel injector for use with an internal combustion engine, the method comprising:assembling a valve group subassembly including a fuel tube and a non-magnetic sleeve extending along a longitudinal axis, the valve group subassembly further including a valve body having an armature, a ball valve fixed to the armature and a valve seat aligned with the longitudinal axis and a first fastening surface; assembling a coil group subassembly including a housing generally surrounding a solenoid coil, the coil group subassembly further including an overmold generally encasing the housing and a second fastening surface; relatively pressing the valve group and the coil group subassemblies along the longitudinal axis such that the fuel tube extends inside the overmold; and matingly engaging the first fastening surface of the valve group subassembly and the second fastening surface of the coil group subassembly so that the valve group subassembly is secured to the coil group subassembly.
- 13. The method according to claim 12, wherein the assembling the valve group subassembly further includes providing a closure member and an armature with an upstream portion, a downstream portion, and an intermediate portion between the upstream and downstream portions, and aligning the closure member and the downstream portion along the longitudinal axis.
- 14. The method according to claim 13, wherein the assembling the valve group subassembly further includes forming a depression in the valve seat and centering the closure member with the depression relative to the longitudinal axis.
- 15. The method according to claim 13, wherein the assembling the valve group subassembly further includes fixing the closure member to the armature and the fixing the closure member to the armature includes welding a valve ball to the armature.
- 16. The method according to claim 12, wherein the assembling the valve group subassembly includes fixing a closure member to an armature.
- 17. A solenoid actuated fuel injector for use with an internal combustion engine, the fuel injector comprising a valve group and a power group, the valve group including: a hydraulic metering subassembly having an elongated inlet tube for conveying fuel from a fuel inlet to a fuel outlet, a non-magnetic sleeve connected to an end of said inlet tube and connected to a valve body assembly having a valve body, an armature and a valve ball coupled to a portion of the armature and movable between valve closed and open positions, the valve group being calibrated independent of said power group, and wherein said inlet tube, non-magnetic sleeve and valve body are hermetically joined together to form said hydraulic metering subassembly.
- 18. A fuel injector for use with an internal combustion engine, the fuel injector comprising:a valve group subassembly being insertable with a coil group subassembly; the valve group subassembly including: a valve body extending along a longitudinal axis, the valve body being connected to a non-magnetic sleeve; a valve seat secured to the valve body, the valve seat defining an outlet opening through which fuel flows; an armature movable along the longitudinal axis with respect to the valve body; and a valve ball fixed to the armature, the valve ball being moved between an open position wherein the valve ball is spaced from the valve seat such that fuel flow through the outlet opening is permitted and a closed position wherein the valve ball contiguously engages the valve seat such that fuel flow is prevented; a first fastening surface; and a coil group subassembly including: a solenoid coil operable to displace the armature with respect to the valve body; a housing generally surrounding the solenoid coil and matingly engaged to the valve body of the valve group subassembly; and a second fastening surface fixed in contiguous engagement with the first fastening surface so that the valve group subassembly is secured to the coil group subassembly.
- 19. The fuel injector according to claim 18, wherein the mating engagement between the first and second fastening features includes welding to retain the valve group subassembly with respect to the coil group subassembly.
- 20. The fuel injector according to claim 18, wherein the valve group comprises a valve ball fixed to the armature.
- 21. The fuel injector according to claim 18, wherein the coil group subassembly further includes:a bobbin defining a winding form for the solenoid coil; and an over-mold generally encasing the housing.
- 22. The fuel injector according to claim 18, wherein the valve group subassembly further includes:a fuel tube extending along the longitudinal axis from an upstream end to a downstream end proximate to the valve body; an adjusting tube disposed within the fuel tube; and a spring applying a biasing force urging the valve ball toward the closed position, the spring extending between the adjusting tube and the armature.
- 23. The fuel injector according to claim 22, wherein the valve group subassembly further includes the fuel tube connecting to the non-magnetic sleeve.
- 24. The fuel injector according to claim 23, wherein the valve group subassembly further includes:a first hermetic joint connecting the non-magnetic sleeve to the fuel tube; and a second hermetic joint connecting the non-magnetic sleeve to the valve body.
- 25. The fuel injector according to claim 24, wherein the first and second hermetic joints include welds.
- 26. The fuel injector according to claim 18, wherein the armature includes an upstream portion receiving fuel, a downstream portion including a fixture securing the valve ball, and an intermediate portion between the upstream and downstream portions.
- 27. The fuel injector according to claim 26, wherein the intermediate portion includes a bore extending along the longitudinal axis and a passage extending from the bore to an exterior surface of the armature.
- 28. The fuel injector according to claim 26, wherein the intermediate portion includes a tubular cylinder and the downstream portion includes an open end of the tubular cylinder.
- 29. The fuel injector according to claim 26, wherein the downstream portion includes a conical depression.
- 30. The fuel injector according to claim 26, wherein the valve ball is a sphere selected from a group consisting of a ball bearing and a gage ball.
- 31. The fuel injector according to claim 26, wherein the valve ball is welded to the downstream portion.
- 32. The fuel injector according to claim 23, wherein the over-mold includes a first connector housing partially surrounding at least one electrical connector, the first connector housing being adapted for electrical communication.
- 33. The fuel injector according to claim 22, wherein a portion of the housing projecting beyond the over-mold and connecting to a shoulder on the valve body, and the housing portion is welded to the valve body shoulder.
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser. No. 08/997,274, filed on Dec. 23, 1997, now U.S. Pat. No. 6,047,907, which is hereby incorporated by reference herein in its entirety.
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Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
08/997274 |
Dec 1997 |
US |
Child |
09/492143 |
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US |